Apparatus and method for producing high density textile sliver



1970 J. R. WHITEHURST 3,533,133

APPARATUS AND METHOD FOR PRODUCING HIGH DENSITY TEXTILE SLIVER Filed Sept. 6, 1968 3 Sheets-Sheet 1 INVENTOR! JbE-BWHITEHURST ATTORNEYS Oct. 13, 1970 J. R. WHITEHURST APPARATUS AND METHOD FOR PRODUCING HIGH DENSITY -TEXTIL'E SLIVER 3 Sheets-Sheet 2 Filed Sept. 6, 1968 BY udZMsf-gag $14M ATTORNEYS 1970 J. R. WHITEHURST 3,533,138

APPARATUS AND METHOD FOR PRODUCING HIGH DENSITY TEXTILE SLIVER Filed Sept. 6, 1968 3 Sheets-Sheet 5 INVENTOR. JoE- RWHITEHURsT ATTORNEYS United States Patent Int. Cl. D01h /72 US. Cl. 19-150 3 Claims ABSTRACT OF THE DISCLOSURE Apparatus and method for controlling textile fibers during their travel from the delivery rolls of a drafting unit to a coil forming member to increase the density and tensile strength of sliver being formed from the fibers and thereby to enable coiling a greater than normal length of sliver in a given size coiler can by immediately condensing a web issuing from the drafting rolls into a sliver, then precompressing the sliver immediately after its formation to increase its density and the cohesion of the fibers therein relative to each other while reducing the cross-sectional area of the sliver, guidingly confining the thus compressed sliver in its path of travel to a coiler trumpet to aid in maintaining the increased density of the sliver and the cohesion of the fibers therein relative to each other while substantially preventing production of fly by substantially shielding the sliver from ambient air, and then. further compressing the sliver while pulling the sliver, from the point at which it is being precompressed, through the trumpet and delivering the sliver to the coil forming member.

This application is a continuation-in-part of my copending application Ser. No. 548,691, filed May 9, 1966, now Pat. No. 3,401,429 and entitled Apparatus for Controlling Sliver Between Drafting Rolls and a Coiler Head.

The apparatus disclosed and claimed in my said copending application significantly reduces the normally occurring substantial increase in the CV. reading of sliver nonuniformity (coefficient of variation of weight per unit length) during travel of the sliver from the delivery rolls of a drafting unit to a coiler by guidingly confining the textile sliver in its path of travel in a guide tube of pre determined internal dimensions so as to maintain substantial cohesion and integrity of the fibers relative to each other.

It is an object of this invention to provide an improved apparatus and method for so controlling a textile sliver in its travel from a drafting unit to a coil forming member as to not only avoid any substantially increase in the CV. reading (nonuniformity) of the sliver, but also to increase the density and consequently reduce the volume per given weight thereof to enable coiling a greater than normal length of sliver in a given size coiler can and to improve the condition of the sliver for subsequent handlings and processes.

According to the instant invention, a fibrous textile web is condensed into a sliver immediately as it emerges from the delivery rolls of a drafting unit, and immediately thereafter, the sliver is precompressed, preferably by means of a first pair of fluted calender rolls, so as to increase its density and increase the cohesion of the fibers therein relative to each other while reducing the crosssectional area of the sliver. Thereafter, the sliver is guidingly confined in its path of travel from a point closely adjacent the first fluted calender rolls to a coiler trumpet to aid in maintaining the increased density of the sliver 3,533,138 Patented Oct. 13, 1970 n, z CC and the cohesion of the fibers therein relative to each other while minimizing production of fly by the sliver. In order to ensure that the increased density, the increased cohesion of the fibers, and the reduced cross-sectional area configuration of the sliver are maintained after the sliver emerges from the first calender rolls and as the sliver is being received by a coil forming member, the sliver is again compressed immediately as it emerges from the second condensing means embodied in the coiler trumpet, preferably by means of a second pair of fluted calender rolls, and the sliver so drawn through the trumpet is then delivered to the rotating coil forming member immediately adjacent the calender rolls.

It is preferred, but not entirely necessary, that both pairs of calender rolls are of the fluted type so that, not only is the sliver compressed at each pair of calender rolls, but the mating flutes of the calender rolls impart increased density to closely spaced areas of the sliver by crimping the sliver transversely thereof during its travel, thereby further increasing the cohesion of the fibers in the sliver relative to each other and greatly increasing the tensile strength of the sliver.

Some of the objects and advantages of the invention having been stated, others will appear as the description proceeds, when taken in connection with the accompanying drawings, in which:

FIG. 1 is a longitudinal vertical sectional view through a portion of a drawing frame, including the drafting rolls and coiler head thereof, and showing a preferred embodiment of the sliver controlling apparatus for carrying out the method of the present invention in association therewith;

FIG. 2 is a perspective view of the improved sliver controlling apparatus of FIG. 1;

FIG. 3 is an enlarged fragmentary vertical sectional view through the delivery rolls of the drafting unit, the sliver condensing means, the first pair of calender rolls, and the ingress end of the sliver guide tube for particularly illustrating the relationship therebetween, with the sliver passing from the condensing means to the sliver guide tube;

FIG. 4 is a fragmentary view of a preferred means for supporting the sliver guide tube;

FIG. 5 is an enlarged elevation, partially in section, taken along line 55 in FIG. 1 and showing a preferred means for supporting the precompressing or first pair of calender rolls and showing portions of the drive means therefor;

FIG. 6 is a fragmentary vertical sectional view taken substantially along line 6--6 in FIG. 4; and

FIGS. 7 and 8 are schematic illustrations of suitable gear arrangements for transmitting rotation from the drafting rolls to the first and second pairs of calender rolls.

Referring more specifically to the drawings, a representative embodiment of novel apparatus for carrying out the method of this invention is shown in association with a drawing frame and is located between a drafting unit .10 and a coiler head 11 (FIG. 1). Drafting unit 10 includes a series of sets of top and bottom drafting rolls including front or delivery rolls 12, 13, rearwardly of which additional sets of upper and lower drafting rolls 14, 15 are provided for drafting textile fibers or textile material T therethrough. Textile material T emerges from delivery rolls 12, 13 in the form of a broad, thin, flat web which is condensed into a sliver S as it passes from delivery rolls 12, 13 through the apparatus of the present invention to a rotary coil forming member or tube gear 21. As shown, tube gear 21 is provided with a downwardly and outwardly inclined passage 22 therein which is open at its upp r end for receiving sliver S and which is open at its lower end for laying sliver in coils in a coiler can 24, as is usual. Tube gear 21 is positioned in an opening through a spectacle 25 carried by a main transverse frame member or beam 26 spaced beneath drafting unit 10.

The term CV. is used throughout the textile industry and in the instant application to mean the coefiicient of variation in the volume of successive portions of a textile sliver, and the term C.V. reading means the percentage of variation in cross-sectional volume of the sliver as calculated in a well-known manner by passing test lengths of sliver through a Stock Variation Analyzer or comparator. One type of testing device commonly used for this purpose is known as a Uster Tester.

As is usual, the textile material T travels a distance of several inches from delivery rolls 12, 13 to tube gear 21, during which the textile material is normally maintained under a slight tension draft and is condensed from a web to a sliver. At high speeds; especially at speeds of more than 700 feet per minute, when the textile material is not controlled in the manner disclosed in my said copending application or in the manner according to the instant invention, the nonuniformity or C.V. reading already in the textile material emerging from delivery rolls 12, 13 is increased substantially as heretofore stated, because the required tension draft produces an abnormal or false draft at previously existing areas of relatively low density in the textile material. It is apparent that such relatively low-density areas are of lesser tensile strength than adjacent areas of high or normal density, and, therefore, the density of such low density areas, and areas contiguous thereto, is further reduced, thereby increasing the C.V. reading of the textile material.

Also, as a consequence of the high speed travel of the material through the air, as it is usually guided to a coiler trumpet, the resistance of the air has the effect of retarding the movement of surface fibers from the moving fibrous mass and thus separates or dislodges many surface fibers; especially relatively short fibers, from the fibrous mass. Such separated fibers further increase the CV. reading of the sliver and are carried into the ambient air as fly and accumulate as lint on various adjacent parts of the drawing frame and on the textile material in process. Such accumulated lint reduces efficiency in operation of the drawing frame and is difficult to remove. Further, the quantity of the sliver is reduced by lint settling upon the sliver.

According to the apparatus and method of the instant invention, the attenuated web of textile material emerging from delivery rolls 12, 13 is so controlled thereafter in its travel to coiler head 11 as to produce sliver having characteristics of high density, high tensile strength and reduced cross-sectional area while substantially preventing the escapement of fibers from the main body of the textile material such as to minimize the accumulation of lint on adjacent parts of the drawing frame and to improve the uniformity of the textile material as compared to the uniformity of textile material which may be attained when utilizing other prior art types of sliver controlling means between the drafting unit and the coiler head of a drawing frame.

By reducing the cross-sectional area of the sliver according to this invention, it is possible to increase by about -l8% the maximum length of sliver of given weight per yard which may be coiled into a given size coiler can as compared to the maximum length of sliver which could be coiled into such a coiler can heretofore. In other words, the number of layers of sliver and the number coils of sliver per layer may be increased substantially in filling a given size can.

Essentially, the apparatus of this invention comprises a first condensing means or web condenser 30, first sliver compressing means 31, sliver guiding and confining means 32, a second condensing means or coiler trumpet 33, and second sliver compressing means 34, all of which are serially arranged between delivery rolls 12, 13 and tube gear 21. The first condensing means or web condenser 30 initially condenses the fibrous web emerging from delivery rolls 12, 13 into a sliver and is preferably in the form of an elongate plate 3011 having a flat, substantially straight, rear surface against which the web emerging from delivery rolls 12, 13 is propelled. The dimension of plate 30a parallel to rolls 12, 13 should be at least equal to the width of the web of textile fibers emerging from delivery rolls 12, 13. It is preferred that plate 30a is spaced within about from delivery rolls 12, 13.

As best shown in FIG. 3, the central portion of condensing plate 30a is provided with a tapered or trumpetshaped opening or passage 30]] therethrough. Generally, the sizes of slivers produced in the textile industry from most textile fibers are in the range of about -70 grains per yard, although there are instances in which slivers as large as 200 grains per yard are produced. Thus, it is peferred that trumpet-shaped passage 30b is defined by a web-condensing trumpet 30c (FIG. 3) which may be pressed lightly into or otherwise removably secured to condensing plate 30a so that a trumpet having a different size of discharge orifice may be used in place of trumpet 300 when a sliver of different weight per yard is to be produced.

It should be noted that trumpet 300 extends through plate 30a, with the smaller or front end portion of trumpet 30c extending forwardly into close proximity to the nip of a pair of upper and lower precompressing calender rolls 31a, 31b which are components of the first sliver compressing means 31. The distance from the front end of trumpet 300 to the nip of calender rolls 31a, 31b should be less than the average staple length of the fibers in the textile material T so as to avoid imparting false draft to the material in this zone. It is preferred that calender rolls 31a, 31b are of the fiuted intermeshing type, although it is to be understood that calender rolls provided with smooth peripheral surfaces may be used, if desired. When the sliver is compressed by smooth calender rolls, it will undesirably expand to a greater extent upon emerging from the calender rolls than is the case when fluted calender rolls are used. Also, fluted calender rolls are preferred because the intermeshing flutes thereof will impart transverse crimp to the sliver being compressed therebetween and thereby further increase the tensile strength of and further reduce the volume per yard and cross-sectional area of the textile material. Calender rolls 31a, 31b are preferably of greater diameter than delivery rolls 12, 13 so they may be provided with relatively larger flutes thereon.

Upper calender rolls 31a may be freely rotatable on a shaft 310, and the driven bottom calender roll 31b transmits rotation to upper calender roll 31a by virtue of the sliver S being compressed therebetween. The surface speed of first calender rolls 31a, 31b should be such relative to the surface speed of delivery rolls 12, 13 as to impart a very small tension draft to the textile material and to pull the textile material, which is being condensed from a web into a sliver by the first condensing means 30, through trumpet 300 A draft of about 1.001 to 1.005 is preferred between delivery rolls 12, 13 and calender rolls 31a, 31b, although the draft in this zone may be increased, if desired.

Drafting unit 10 may be driven in any desired or wellknown manner and rotation may be imparted to the first pair of calender rolls 31a, 31b by a suitable train of gears a-d (FIG. 7) connecting bottom delivery roll 13 with bottom calender roll 31b. As shown in FIGS. 5 and 7, gears a, d are fixed to corresponding ends of rolls 13, 13b, and mesh with respective intervening change gears b, c fixed in axial relation to each other and journaled on a standard 40 carried by beam 26. The tension draft in the zone between delivery rolls 12, 13 and calender rolls 31a, 31b may be varied by replacing certain of the gears a-d with gears of other sizes, as desired.

As shown in FIG. 5, reduced opposed ends of bottom calender roll 3112 may be journaled in suitable bearings 41, 42 mounted in respective slide blocks 43, 44 and suitably adjustably secured to conventional roll stands 45, 46 carried by beam 26. Slide blocks 43, 44 may be of the usual type used for drafting rolls and having U-shaped slots therethrough for receiving the bearings 41, 42 therein.

The upper calender roll 31a preferably is mounted so that it may be readily lifted away from lower or bottom calender roll 31b to facilitate the threading of textile material through trumpet 300 of first condensing means 30 and between calender rolls 31a, 31b. Also, means are provided for limiting the extent of intermeshing relationship between calender rolls 31a, 31b to prevent the teeth of the flutes of upper calender roll 31a from engaging the grooves between the teeth of the flutes of the lower or bottom calender roll 31b, and vice versa. The depth of intermeshing of the flutes of calender rolls 31a, 31b also controls to some extent the speed at which the sliver S is advanced by calender rolls 31a, 31b.

Accordingly, it will be observed in FIG. that reduced opposed ends of shaft 31c of upper calender roll 31a are journaled in respective bearings 50, 51, each of which has an enlarged portion or spacing member 52 thereon which normally rests against a corresponding enlarged portion 53, there being one of the enlarged portions 53 provided on each of the bearings 41, 42. The diameter of enlarged portions 52, 53, associated 'with upper and lower calender rolls 31a, 31b, is such as to limit the intermeshing relationship of calender rolls 31a, 31b to a predetermined extent. Bearing 50 is pivotally mounted, as at 55, in the upper portion of slide block 43, but bearing 51 is freely positioned in slide block 44. Thus, upper calender roll 31a may be readily titled upwardly away from bottom calender roll 3112 about the pivot point 55 to thereby permit ready access to trumpet 300 of first condensing means 30, when desired.

As best shown in FIG. 2, the upper portion of condensing plate 30a and its trumpet 300 are provided with a narrow slot 30d extending from the top edge of condensing plate 30a to the discharge orifice of trumpet 30c to facilitate threading textile material T into the trumpetshaped passage 30b. Depending upon the weight per yard of the stock being processed, the slot 30d may be about to wide at the trumpet orifice and is preferably slightly wider at the upper edge of condensing plate 30a. Opposite ends of condensing plate 30a may be suitably removably supported on slide blocks 43, 44.

Suitable weighting means may be associated with upper calender roll 31a so that it will apply the desired amount of compression to the sliver passing between rolls 31a, 31b. In this instance, the weighting means takes the form of a pair of sleeves 56 mounted on shaft 31c and extending between opposite ends of calender roll 31a and the proximal surfaces of the enlarged portions 52 of bearings 50, 51.

The sliver guiding and confining means 32 comprises an elongate sliver guide tube 32a, open at both ends, and whose rear or ingress end is positioned forwardly of and in closely spaced relation to the nip of first calender rolls 31a, 31b. The diameter or cross-sectional area of tube 32a is substantially less than that of the larger or open upper end of coiler trumpet 33, so that the egress or exit end portion of tube 32a may extend downwardly within and be encircled by the internally tapered upper portion of coiler trumpet 33. The internal diameter or cross-sectional area of tube 32a is substantially greater, however, than that of the discharge orifice of each trumpet 30c, 33.

It is preferred that the proximal end portions of trumpet 30c and sliver guide tube 32a are positioned between the arcs defined by the peripheral surfaces of first calender rolls 31a, 31b, or at least the distance from the nip of rolls 31a, 31b to the proximal ends of trumpet 30c and tube 32a should be less than the average staple length of the fibers in the sliver. Thus, the sliver enters the tube before it has fully expanded to the extent to which it can inherently after having been precompressed by rolls 31a, 31b. Also, the ambient air will not then be as effective in expanding the sliver as it would be if the tube 32a were spaced from the nip of rolls 31a, 31b a distance equal to or greater than the average staple length.

The axes of web-condensing trumpet 30c and the rear end of sliver guide tube 32a preferably are spaced a short distance above the common plane of the nips of delivery rolls 12, 13 and first calender rolls 31a, 31b as represented by the broken lines in the central portion of FIG. 3. This distance may be about to and, because of its larger size, the axis of tube 32a may be located further above said common plane than the axis of trumpet 30c. Such arrangement is desirable because, for various reasons such as heat generated by the drafting rolls, the ambient air is in constant motion and tends to rise from beneath the drafting rolls and the calender rolls 31a, 3111. Consequently, the web emerging from delivery rolls 12, 13 and the sliver emerging from calender rolls 31a, 31b tend to move upwardly. Thus, the trumpet 300 is positioned above the plane of the nips of rolls 12, 13; 31a,

31b so as to be aligned with the normal path of the web emerging from delivery rolls 12, 13. Thereafter, the sliver being formed through passage 30b is pulled downwardly by calender rolls 31a, 31b and, since the axis of the ingress end of tube 32a is above the plane of the nips of rolls 12, 13; 31a, 31b, the sliver is directed from the nip of rolls 31a, 31b generally toward the bottom portion of the wall of tube 32a so the sliver will not tend to move over the upper edge of the mouth of tube 32a.

As the compressed sliver emerges from between first calender rolls 31a, 31b, it is in a somewhat flattened condition and the sliver expands to some extent. Therefore, the ingress end of tube 32a is preferably provided with an internal shoulder or ridge 320 (FIG. 3) around its inner periphery which may project inwardly about to 4 so as to define a restriction at the ingress end of tube 32a which aids in gathering the sliver into the tube 32a and will permit some expansion of the sliver after it enters the tube. In so doing, the ridge conditions the sliver to reduce friction between the sliver and the length of the confining passage defined by tube 32a during further travel of the sliver through tube 32a.

The second compressing means 34 is embodied in a pair of fluted calender rolls 34a, 34b positioned between and closely adjacent coiler trumpet 33 and the open upper end of passage 22 in tube gear 21. In the second embodiment of the apparatus disclosed in my said copending application Ser. No. 548,691, calender rolls are also positioned between a condensing trumpet adjacent the delivery rolls of a drafting unit and the ingress end of a sliver guide tube. However, since the apparatus of said copending application is devoid of calender rolls between the exit end of its sliver guide tube and the tube gear, the sliver travels about twice as far between the calender rolls adjacent the ingress end of the sliver guide tube and the point forwardly thereof at which a pulling force is being applied to the sliver than is the case in the present invention. Not only is the distance from the aforementioned calender rolls of said copending application to the point at which the pulling force is being applied to the sliver much greater than is the case in the present invention, but the sliver is not subjected to a second. condensing and compressing action adjacent the inlet of the tube gear passage. The inherent nature of attenuated textile sliver is such that, within certain limits, the greater the distance between the point at which a sliver is being delivered by rolls and the succeeding point at which the sliver is being taken up, the greater is the tendency for the sliver to expand. Thus, it follows that a sliver will expand a considerably greater amount in its course from the web-condensing trumpet to the bottom of the coiler tube gear of said copending application than it will utilizing the second compressing or calender rolls 34a, 34b according to the instant invention.

By providing calender rolls between the coiler trumpet 33 and the tube gear 21 as disclosed herein, a sliver of given weight per yard is of relatively smaller cross-sectional area and, therefore, sliver guide tube 32a may be of smaller internal diameter or internal cross-sectional area throughout a major portion of its length than that of the sliver guide tube disclosed in said copending application to accommodate a given size sliver. For example, to accommodate sliver in the range of about 50 to 70 grains per yard, the internal diameter of the major portion of sliver guide tube 32a of the present invention should be about A" to (0.49 to 0.077 square inch internal crosssectional area) in order to properly guidingly confine the sliver in its path of travel, at relatively high speeds of 700 feet per minute or greater, to the second calender rolls 34a, 34b while maintaining the cohesion and integrity of the fibers relative to each other so that the increase in the CV. reading (nonuniformity) of the sliver is no more than about 0.5. However, in the processing of very heavy slivers, such as 150 grains per yard, the internal cross-sectional area of sliver guide tube 32a may be about 0.300 square inch, which is within the range of the internal cross-sectional area of the sliver guide tube set forth in my said copending application, namely, about 0.150 to 0.300 square inch to internal diameter).

In any event, the internal cross-sectional area of tube 32a should be sufficient to ensure that the tube will not interfere with the travel of the sliver therethrough, and the maximum internal cross-sectional area of tube 32a relative to the cross-sectional area of the sliver S should be such that the tube will shield the sliver in its travel from first calender rolls 31a, 31b to trumpet 33 from the friction of ambient air against the sliver. In the absence of tube 32a, as a consequence of high speed travel of the sliver through the air, the resistance of the air would have the effect of retarding the movement of surface fibers from the moving fibrous mass and thus would separate or dislodge many surface fibers; especially relatively short fibers, from the fibrous mass. Such separated fibers further increase the C.V. reading of the sliver and are carried into the ambient air as fly and settle and accumulate as lint on various adjacent parts of the drawing frame and on the textile material in process. Such accumulated lint reduces efficiency in operation of the drawing frame and is diflicult to remove. Further, the quality of the sliver is reduced by lint settling upon the sliver.

It is preferred that the exit end of sliver guide tube 32a is positioned within the upper portion of coiler trumpet 33, as heretofore described, in order to ensure that a minimum of air turbulence may be created between the end of tube 32a and the area of trumpet 33 at which maximum condensing of sliver S is effected by the relatively small or restricted lower orifice of trumpet 33. Otherwise, the sliver S may expand or open up as it emerges from the egress end of tube 32a and thus may be ruptured at this area, or the expanding or opening of the fibers in the sliver S may choke the coiler trumpet 33 so that the second calender rolls 34a, 341) may then rupture and part the sliver adjacent the point at which it emerges from the lower end of trumpet 33. Also, by positioning the egress end portion of sliver guide tube 32a within the enlarged upper portion of the passage through trumpet 33, the prevention of expansion of the fibers thus assured prevents the escapement of lint or fly from sliver S. Tube 32a is preferably of circular internal cross section, but may be of somewhat oblong or eliptical cross section with out departing from the invention.

To facilitate manually threading the textile material through sliver guide tube 32a, it is provided with a very narrow threading slot 32b throughout the length thereof which extends radially through the wall of tube 3211. As shown in FIG. 2, it is preferred that threading slot 32b is formed in the upper portion of the tube 32a at the ingress 8 end of tube 32a and extends for a relatively short distance along the length of the tube and then curves downwardly, with the major length of slot 32b being formed in one side of tube 32a as opposed to being formed in the upper wall portion thereof. This arrangement of the slot 32b facilitates the threading of the sliver into the ingress end portion of the tube and, since tube 32a curves downwardly to the lower level of trumpet 33, by providing the major length of slot 32b in the sidewall portion of sliver guide tube 320, the sliver will not be thrown against that portion of the wall of the sliver guide tube having the threading slot therein. This reduces scufling of the sliver and also avoids the problem of small fibers being removed from the sliver by the wall of the sliver threading slot 32b.

Slot 32b is substantially less width than the width of the sliver S passing through sliver guide tube 32a. Depending upon the size of the sliver, as stated earlier herein, sliver guide tube 32a may have an internal diameter of about W to A", and slot 32b in tube 32a may be about to wide throughout the major portion of its length.

The second calender rolls 34a, 34b of sliver com pressing means 34 may be of conventional type commonly used in association with the coiler heads of drawing frames. Although calender rolls 34a, 34b are preferably of the fluted type for the same reasons given with respect to first calender rolls 31a, 3112, the second calender rolls may have smooth peripheral surfaces, if desired. Roll 34a may be fixed on its shaft 340 and calender roll 34b may be journaled on its shaft 34d. Further, spacing means, not shown, may be provided for maintaining rolls 34a, 34b in the desired interrneshing relationship similar to the spacing members or enlarged portions 52, 53 of the bearings 50, 51, 41, 42 of FIG. 5, for example.

The shafts 34c, 34d of the second pair of calender rolls 34a, 34b may be mounted in a conventional manner and, therefore, a further description of the supporting means for the second pair of calender rolls 34a, 34b is deemed unnecessary. Calender roll shaft 34c may be driven in a conventional manner, as by a train of gears e-j (FIG. 8) connecting the delivery roll 13 to. shaft 340. The effective surface speed of the second pair of calender rolls 34a, 34b should be such as to apply a tension draft to the sliver sufficient to pull the same from the nip of the first pair of calender rolls 31a, 3117, through sliver guide tube 32a, and through coiler trumpet 33, and to deliver the thus compressed, high density sliver into the passage 22 of rotary coil forming member 21 to be coiled into can 24. A relatively low tension draft, as compared to that normally required, may be imparted to the sliver in its travel between the first and second pairs of calender rolls 31a, 31b, and 34a, 34b so as to substantially eliminate the possibility of imparting any false draft to the sliver in this zone. For example, in the absence of applicants invention, it is customary to apply a draft of from about 1.08 to 1.12 to the sliver. According to the present method, however, because of the increased tensile strength and high density of the sliver, the amount of tension draft between calender rolls 31a, 31b and calender rolls 34a, 34b may be as low as 1.010 or under.

By the arrangement of the condensing means 30, 33, the compressing means 31, 34, and the sliver guiding and confining means 32 according to this invention, the exit ends of the trumpets 30c, 33 may be substantially smaller than has been the case heretofore, thus further reducing the cross-sectional area of a sliver per given weight per unit length. For example, in processing a 60 grain per yard sliver, the smaller or discharge end of the passage 30b in web condensing trumpet 30c may be about .140 to .150 inch and, whereas the diameter of the small end or orifice of a coiler trumpet normally is about .135 inch, it has been found that the orifice of the coiler trumpet 33 associated with the present invention now may be reduced to about .110 to .125 inch diameter, thus further con densing and reducing the cross-sectional area of the sliver.

The distance from the egress end of coiler trumpet 33 to the nip of second calender rolls 34a, 34b also is less than the average staple length of the fibers in sliver S to avoid imparting a false draft to the sliver in this zone.

In order to support sliver guide tube 32a so that its ingress end may be positioned closely adjacent the nip of first calender rolls 31a, 31b and between the arches of the first calender rolls, and so that the exit or egress end of tube 32a may be positioned within the internally tapered upper portion of trumpet 33 without engaging the wall thereof, tube 32a has a downwardly projecting rib or plate portion 60 depending therefrom adjacent its ingress end and through which a pair of longitudinally spaced pins 61, 62 extend laterally. Opposite ends of pins 61, 62 extend loosely into respectively notches r grooves 63, 64 (FIG. 4) in the bifurcated upper portion of a bracket 66 provided with two downwardly extending legs 67 which are adapted to straddle the conventional coiler trumpet support arm 70 shown in FIG. 1. The lower ends of legs 67 rest upon beam 26 and are held in the desired position by upstanding pins 71 on the beam 26 which loosely penetrate suitable openings provided in the rear lower portions of the legs 67. Thus, bracket 66 may be readily removed from beam 26 simply by raising the same upwardly free of pins 71.

Referringagain to FIG. 4, it will be observed that the rear notch '64 in the bifurcated upper portion of bracket 66 is formed somewhat in the manner of a bayonet slot so that, in order to remove the sliver guide tube 32a from bracket 66, when desired, it is simply necessary for the operative to raise the forward end of tube 32a upwardly so that it clears the upper end of trumpet 33 and so that the front pin 61 clears the front portion of the upper edge of bracket 66. Thereupon, tube 32a is moved forwardly, as pin 62 is slid along bayonet slot 64 in bracket 66, and then lifted upwardly to remove sliver guide tube 32a from the bifurcated upper portion of bracket 66.

In operation, it is thus seen that the web of textile material T emerging from delivery rolls 12, 13 is propelled against the rear surface of condensing plate 30a, which is positioned closely adjacent the front surfaces of delivery rolls 12, 13. Plate 30a then guides and gathers the web into the passage 30]; of trumpet 300 where the textile material is condensed into a small sliver. As the first pair of calender rolls 31a, 31b pulls the sliver through trumpet 300, they immediately compress the sliver.

The second pair of calender rolls 34a, 34b then aids in retaining the compressed state of the sliver to a substantial degree, even though the sliver expands a relatively small amount as it leaves the nip of the first pair of calender rolls 31a, 31b. If the calender rolls 31a, 31b are fluted, as preferred, the sliver is also crimped transversely thereof at the same time that it is compressed, thereby further increasing the density and tensile strength of the sliver and further ensuring a reduced volume per given weight of the sliver or, in other words, a retentive relatively reduced cross-sectional area in sliver as it is pulled from the first calender rolls 31a, 31b to the second calender rolls 34a, 34b.

The second condensing means then further condenses the sliver'as it is thereafter compressed and crimped a second time by the calender rolls 34a, 34b and then delivered into the passage 22 of coil-forming member 21 to be coiled into the can 24.

It is thus seen that I have provided an improved method and apparatus for forming a fibrous web being delivered from a drafting unit into a sliver having characteristics of high density, high tensile strength, reduced volume per given weight per unit length and reduced crosssectional area per given weight per unit length, while maintaining the cohesion and integrity of the fibers in the sliver relative to each other so that there is very little increase in the CV. reading (nonuniformity) of the sliver in its course to a coil forming member. Also, it is seen that, since the sliver being formed is of reduced crosssectional area for a given weight per unit length as compared to slivers produced by prior methods and apparatuses, a substantially greater length of sliver of given weight per unit length may be coil-ed into a sliver can of given size than has been the case heretofore, since a greater number of layers of sliver of given weight per yard and a greater number of coils of sliver per layer may now be positioned in a sliver can of given size than has been practical heretofore to my knowledge.

In the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

I claim:

1. Apparatus for controlling fibrous textile material in its course from delivery rolls of a drafting unit to a rotary coil forming member; said apparatus comprising a condensing plate closely adjacent the delivery rolls and having a trumpet-shaped passage therethrough for condensing a fibrous web emerging from the delivery rolls into a sliver,

a first pair of rotatable fluted intermeshing calender rolls for calendering, crimping and pulling the sliver through said trumpet-shaped passage,

said trumpet-shaped passage of said condensing plate terminating between the arcs of the first pair of calender rolls closely adjacent the nip thereof,

a second pair of rotatable fluted intermeshing calender rolls adjacent said coil forming member and arranged to calender, crimp and pull said sliver from said first calender rolls and to deliver the sliver to said coil forming member,

a sliver condensing coiler trumpet disposed closely adjacent the nip of said second pair of calender rolls,

an elongate sliver guide tube for guidingly confining the sliver in its path of travel from said first calender rolls into said coiler trumpet and having an ingress end positioned closely adjacent the nip of and between the arcs of said first pair of calender rolls,

the internal cross-sectional area of said sliver guide tube being within the range of about .049 to .077 square inch for readily accommodating sliver in the range of about 50 to 70 grains: per yard and wherein the ingress end of said sliver guide tube is provided with an internal shoulder around its inner periphery defining a restriction to aid in imparting cohesiveness to the sliver passing through said guide tube,

the hips of said delivery rolls and said first calender rolls being disposed in a common substantially horizontal plane with respect to each other and wherein the axes of the discharge orifice of said trumpetshaped passage and the ingress end of said sliver guide tube are each disposed a predetermined distance above said horizontal plane, and

drive means operatively connecting the drafting unit to one of the calender rolls of each pair.

2. Apparatus for controlling fibrous textile material in its course from delivery rolls of a drafting unit to a rotary coil forming member and wherein the drafting unit includes a beam extending beneath said delivery rolls; said apparatus comprising a condensing plate closely adjacent the delivery rolls and having a trumpet-shaped passage therethrough for condensing a fibrous web emerging from the delivery rolls into a sliver.

a first pair of rotatable fluted intermeshing calender rolls for calendering, crimping and pulling the sliver through said trumpet-shaped passage,

a second pair of rotatable fluted intermeshing calender rolls adjacent said coil forming member and ar ranged to calender, crimp and pull said sliver from said first calender rolls and to deliver the sliver to said coil forming member,

1 1 a sliver condensing coiler trumpet disposed closely adjacent the nip of said second pair of calender rolls, an elongate sliver guide tube for guildingly confining the sliver in its path of travel from said first calender rolls into said coiler trumpet, drive means operatively connecting the drafting unit to one of the calender rolls of each pair, and means mounting said sliver guide tube on said beam and comprising a downwardly projecting rib fixed to said tube adjacent its ingress end and having a pair of substantially horizontally spaced laterally projecting pins thereon, and a bracket mounted on said beam and projecting upwardly therefrom forwardly of said first calender rolls and having a bifurcated portion on its upper end adapted to receive said downwardly projecting rib therein, said bifurcated upper portion having a pair of longitudinally spaced notches in its upper surface with the rearmost notch being substantially L-shaped such that the corresponding pin on said rib may be moved downwardly thereinto and then rearwardly, and the other of said notches being located so as to receive the other of said pins when said one pin occupies the latter rearward position. 3. A method of producing a high density sliver during continuous travel of textile fibers from a drafting unit to a rotatable coiler member; said method comprising the successive steps of condensing a web of textile fibers emerging from the drafting unit into a sliver closed adjacent the drafting unit,

calendering the sliver to compress the same at a point less than the average staple length of the fibers in the sliver from the point where the web is condensed to form the sliver to avoid imparting false draft to the sliver passing therebetween while imparting crimp thereto and while applying a minute tension draft of about 1.001 to 1.005 to the sliver sufiicient to pull the fibers through the condensing step,

guidingly confining the crimped sliver in an elongate passage from a point less than the average staple length of the fibers in the sliver from the point of calendering of the sliver to substantially prevent escapement of lint from the sliver passing therebetween to a point adjacent the coiler member so as to substantially prevent escapement of lint therefrom,

condensing the crimped sliver as it emerges from the elongate passage,

again calendering the sliver while imparting additional crimp thereto and while applying a relatively low tension draft of about 1.010 to the sliver such as to pull the sliver from the first point of calendering through the elongate passage without imparting false draft to the sliver and delivering the sliver to the coiler member, and

wherein the condensing of the web into a sliver and the condensing of the crimped sliver emerging from the elongate passage include respective passage thereof through increasingly restricted passageways.

References Cited UNITED STATES PATENTS 1,053,224 2/1913 Rooney l9288 XR 2,878,527 3/1959 Whitehurst 19-159 3,304,584 2/1967 West et a1. 19-159 XR 3,377,665 4/1968 Kincaid 19159 XR OTHER REFERENCES Publication: Web Control distributed at textile show, Greenville, SC, October 1964, pp. 19-157.

35 DORSEY NEWTON, Primary Examiner US. Cl. X.R. l9157 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 138 Dated October 13, 1970 InventorQQ J. R. Whitehurst It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3, Line 45, "quantity" should be -quallty-; same column Line 68, after "number" and before "coils" insert -of-. Column 4, Line 19, "peferred" should be -preferred-. Column 7, Line 14, "0.49" should be --0.049-. Column 8, Line 15, after "32b' insert --of-. Column 9, Line 15 "respectively" should be --respective--. CLAIM 2, Column 11, Line 3, "guildingly" should be --guidlngly-. CLAIM 3, Column 11, Line 32, "closed" should be --closely.

mm m! SEALED [IE-029 1:370

Attest:

Edward M. Fletcher, It.

Attesting Officer FORM PC4050 nosg) USCOMMDC scam-seq U S GOVERNMENT FIUN'ING OFFK'F I96! O- 366'!3l 

